Hydro Generator Turbine

The Situation

Qualtex was engaged to install a hydro generator turbine runner onto the main shaft — a precision-critical task where correct fitment directly affects the reliability and performance of the entire generating unit.

The Challenge

Fitting a turbine runner of this type demands both specialised equipment and the expertise to use it correctly. The consequences of a poor installation — misalignment, improper coupling engagement, or incorrect interference fit — are significant, with the potential for premature wear, vibration, or failure of a high-value, difficult-to-access asset.

What Qualtex Did

Qualtex technicians utilised their own high-pressure oil injection equipment to mount the turbine runner onto the main shaft. This technique expands the bore of the component during fitting, allowing precise positioning without the mechanical force that can damage mating surfaces. The fitment was completed without technical issues and on schedule.

With the runner installed, the turbine and generator shafts were connected using an SKF OK Coupling — an arrangement that also employs high-pressure oil injection to mount the coupling across both shafts. Once hydraulic pressure is released, the interference fit generates the clamping force that allows the coupling to transmit torque and axial load through friction alone, with no mechanical fasteners carrying the primary load.

With the drive-train fully assembled, precision laser alignment was carried out across the complete shaft system.

The Outcome

The turbine runner and coupling were installed safely, on time, and to specification. The use of high-pressure oil injection technology — applied by technicians with deep practical experience of the method and safe use— ensured the interference fits were achieved without risk to the components. The completed drivetrain left site precisely aligned and ready for service.